CN110475599A

CN110475599A - Honeycomb ceramics, particulate filter and the extrusion die for it of pattern blocking

Info

Publication number: CN110475599A
Application number: CN201880023128.6A
Authority: CN
Inventors: D·M·比尔; D·C·伯克宾德; P·坦登
Original assignee: Corning Inc
Current assignee: Corning Inc
Priority date: 2017-01-31
Filing date: 2018-01-31
Publication date: 2019-11-19
Anticipated expiration: 2038-01-31
Also published as: US10940421B2; CN110475599B; JP7111741B2; EP3576862A1; US20190374896A1; WO2018144532A1; JP2020506869A; MX2019009034A; US20210154612A1; US11213781B2

Abstract

A kind of honeycomb ceramics of the porous wall with intersection comprising first to fourth duct, wherein each duct extends to exit face from inlet face and is blocked to limit the constitutional repeating unit having there are three import and one outlet channel.Constitutional repeating unit includes first passage, and it includes length L₁, width W₂With area A₁；Second channel, it includes length L₂, width W₂With area A₂；Third channel comprising length L₁, width W₁With area A₃And fourth lane comprising length L₂, width W₁And A₄, wherein first to third channel is import, and fourth lane is rectangular outlet, and meets W₁>W₂And L₁≠L₂At least one of, that is, W₁>W₂Or L₁≠L₂Or W₁>W₂And L₁≠L₂.Constitutional repeating unit has quadrilateral periphery.Provide the particulate filter comprising the honeycomb ceramics, honeycomb extrusion die and the method for manufacturing honeycomb ceramics.

Description

Honeycomb ceramics, particulate filter and the extrusion die for it of pattern blocking

Beauty of the application according to the Serial No. 62/452,770 for requiring to submit on January 31st, 2017 of 35U.S.C. § 119 The benefit of priority of state's provisional application based on content of the application and is incorporated herein by reference in their entirety herein.

Technical field

This disclosure relates to which honeycomb ceramics is for example suitable for (such as starting from fluid stream more particularly, to porous ceramic honeycombs Machine exhaust) filtering particle particulate filter, and the extrusion die for it.

Background technique

Honeycomb particulate filter generally includes honeycomb ceramics, the porous ceramic walls with multiple intersections, thus Formation cross-section The identical axially extending channel of product.Half in these channels is blocked on inlet side with checkerboard pattern, and these are identical Channel be not blocked on outlet side, therefore form exit passageway.The other half in axially extending channel is in outlet side On be blocked with checkerboard pattern, and be not blocked on inlet side, therefore form intake channel.When in use, engine is arranged Flow of air flows through from engine exhaust by the porous ceramic walls of honeycomb ceramics and filters out particle (soot and other inorganic particulates Grain).

Some amplifier case constructions cover the transformation to the honeycomb of honeycomb ceramics, with more logical than outlet comprising sectional area The intake channel in road bigger (that is, bigger inlet openings front face area).Since soot and soot load increase with the time, Relatively large intake channel has significantly reduced the increased severity of pressure drop.However, the import that manufacture is increasing The manufacture that duct (and/or smaller and smaller outlet duct) can lead to honeycomb becomes relatively expensive, and may cause it He limits performance.Therefore, seeking soot and soot load ability is relatively high, pressure drop performance is improved and inexpensively manufactures Honeycomb design.

Summary of the invention

In an aspect, a kind of honeycomb ceramics is provided.The honeycomb ceramics includes the base comprising constitutional repeating unit pattern The porous wall of intersection in matter.Each constitutional repeating unit includes the first duct, the second duct, third duct and the 4th duct, Wherein, each duct extends parallel to each other on the axial direction from inlet face to exit face, and orthogonal with axial direction Transverse plane in have quadrangular section.The duct, which is blocked, to be clogged to limit intake channel in constitutional repeating unit and go out Mouthful channel, wherein each constitutional repeating unit includes: first passage, second channel, third channel and fourth lane, and described the One channel is formed by the first duct, and in cross-section includes length L₁, width W₂With sectional area A₁, the first passage tool There are the first side wall and the second sidewall orthogonal with the first side wall；The second channel is formed by the second duct, and transversal It include length L in face₂, width W₂With sectional area A₂, and it shares second sidewall with first passage；The third channel is by Three ducts are formed, and in cross-section include length L₁, width W₁With sectional area A₃, it includes third side walls, and with first Channel shares the first side wall；The fourth lane is formed by the 4th duct, and in cross-section includes length L₂, width W₁With Sectional area A₄, and it shares the 4th side wall with second channel and shares third side wall with third channel.First, second and Triple channel includes intake channel, and fourth lane includes the exit passageway that cross section is rectangular shape, and wherein, meets W₁≥ W₂And L₁≠L₂At least one of, that is, W₁≥W₂Or L₁≠L₂Any one of or W₁≥W₂And L₁≠L₂.In addition, repeating to tie Structure unit includes quadrilateral periphery.

In another aspect, a kind of honeycomb ceramics is provided.The honeycomb ceramics includes comprising constitutional repeating unit pattern The porous wall of intersection in matrix.The constitutional repeating unit has 0.006 inch of (0.152mm)≤Tw≤0.010 inch (0.254mm), 40%≤%P≤60%, 10 microns≤MPS≤16 micron and 38%≤import OFA≤62%, wherein it is each A constitutional repeating unit includes the first duct, the second duct, third duct and the 4th duct.Each duct is from inlet face to out It extends parallel to each other on the axial direction in mouth face, and there is quadrangular section in the transverse plane orthogonal with axial direction. The duct, which is blocked, to be clogged to limit intake channel and exit passageway in constitutional repeating unit, wherein each repetitive structure list Member includes: first passage, second channel, third channel and fourth lane, and the first passage is formed by the first duct, and It include length L in cross section₁, width W₂With sectional area A₁, the first passage has the first side wall and orthogonal with the first side wall Second sidewall；The second channel is formed by the second duct, and in cross section includes length L₂, width W₂With sectional area A₂, And it shares second sidewall with first passage；The third channel is formed by third duct, and in cross section includes length L₁, width W₁With sectional area A₃, it includes third side walls, and share the first side wall with first passage；The fourth lane is by Four ducts are formed, and in cross section include length L₂, width W₁With sectional area A₄, and it shares the 4th side with second channel Wall and third side wall is shared with third channel.First, second, and third channel includes intake channel, and fourth lane includes cross Section is the exit passageway of rectangular shape, wherein meets W₁≥W₂And L₁≠L₂At least one of, and constitutional repeating unit Include quadrilateral periphery.Tw is lateral wall thickness, and %P is the open porosity of porous wall, and MPS is mean pore sizes (D50), and Import OFA is the inlet openings area of honeycomb ceramics.

In another aspect, a kind of honeycomb extrusion die is provided.The honeycomb extrusion die includes die body, into Mouth face, the exit face opposite with inlet face extend to multiple feed openings in die body from inlet face, and prolong from exit face The slit array of intersection for reaching in die body and being connect with the multiple feed opening.The slit array of intersection is included in whole The first slit extended on a exit face, and the second slit that is orthogonal with the first slit and also extending on entire exit face Group.The slit array of intersection forms repetitive unit die head channel pore array, wherein repetitive unit die head duct includes the first die section Part, the second part of the die head, third part of the die head and the 4th part of the die head, first part of the die head includes length in cross section L_1’, width W_2’With sectional area A_1’；Second part of the die head includes length L in cross section_2’, width W_2’With sectional area A_2’；Institute Stating third part of the die head in cross section includes length L_1’, width W_1’With sectional area A_3’；And the 4th part of the die head is in section In include length L_2’, width W_1’With sectional area A_4’, wherein the 4th part of the die head includes the section of rectangular shape.Unit die holes The peripheral shape in road is quadrangle.The construction of part of the die head is selected to provide in the first construction or the second construction at least It is a kind of, in which: first is configured to W_1’>W_2’And L_1’=L_2’And A_4’=A_3’>A_2’=A_1’, and the second construction is in following It is a kind of:

L_1’≠L_2’And A_4’>A_3’>A_2’<A_1’,

L_1’≠L_2’And A_4’>A_2’>A_3’<A_1’,

L_1’≠L_2’And A_3’>A_4’>A_1’<A_2’, or

L_1’≠L_2’And W_1’=W_2’And A_4’=A_2’>A_3’=A_1’。

Other multiple features and aspect are provided according to these embodiments and other embodiments of the disclosure.According to The other feature and aspect of lower specific embodiment, the appended claims and attached drawing, embodiment will be apparent.

Detailed description of the invention

Attached drawing described below for illustration purposes, and is not drawn necessarily to scale.Attached drawing is not intended to any side Formula limits the scope of the present disclosure.Identical element is indicated using identical label in the whole instruction and attached drawing.

Figure 1A instantiates the partial end view of the inlet side of the honeycomb ceramics according to one or more embodiments.

Figure 1B instantiates the portion of the constitutional repeating unit of the honeycomb ceramics of Figure 1A according to one or more embodiments Divide the view of amplification inlet side.

Fig. 1 C instantiates the honeycomb intercepted according to one or more embodiments along the section line 1C-1C of Figure 1A The fragmentary sectional side view of body.

Fig. 1 D instantiates the honeycomb intercepted according to one or more embodiments along the section line 1D-1D of Figure 1A The fragmentary sectional side view of body.

Fig. 1 E instantiates the end-view of the inlet side of the honeycomb ceramics according to one or more embodiments.

Fig. 1 F instantiates the end-view of the outlet side of the honeycomb ceramics according to one or more embodiments.

Fig. 1 G instantiates the cellular component of the honeycomb ceramics according to one or more embodiments comprising multiple assemblings Inlet side end-view.

Fig. 2 instantiates the portion of the particulate filter according to one or more embodiments comprising honeycomb ceramics of the present invention Partial cross-section side view.

Fig. 3 instantiates the schematic side view of the exhaust system of internal combustion engine, the exhaust according to one or more embodiments System includes the particulate filter containing honeycomb ceramics of the present invention.

Fig. 4 A instantiates another bee comprising interleaved units duct construction according to one or more embodiments The partial end view of the inlet side of nest body.

Fig. 4 B instantiates putting for the constitutional repeating unit of the honeycomb ceramics of Fig. 4 A according to one or more embodiments Big end-view.

Fig. 5 instantiates the amplification of the constitutional repeating unit of another honeycomb ceramics according to one or more embodiments View, wherein W₂=L₁=L₂。

Fig. 6 instantiates the amplification of the constitutional repeating unit of another honeycomb ceramics according to one or more embodiments End-view, wherein W₂>L₁And W₂>L₂And L₁=L₂。

Fig. 7 instantiates the amplification of the constitutional repeating unit of another honeycomb ceramics according to one or more embodiments View, wherein W₁>W₂And L₁≠L₂。

Fig. 8 A instantiates the portion of the honeycomb extrusion die of one or more embodiments for manufacturing honeycomb ceramics of the present invention Divide front view.

Fig. 8 B instantiates the honeycomb of Fig. 8 A according to one or more embodiments along section line 8B-8B interception The fragmentary sectional side view of extrusion die.

Fig. 8 C instantiates the die unit hole of the honeycomb extrusion die of Fig. 8 A according to one or more embodiments The amplification front view in road.

Fig. 8 D-8F instantiates the partial front view of honeycomb extrusion die according to one or more embodiments, it illustrates Various feed opening constructions.

Fig. 9 A-9B instantiates description honeycomb ceramics of the present invention according to one or more embodiments and compares honeycomb ceramics comparative example 1- The performance map of 3 pressure drop performance.

Figure 10 instantiates the side of particulate filter of the operation comprising honeycomb ceramics of the present invention according to one or more embodiments The flow chart of method.

Specific embodiment

The illustrative embodiments of the disclosure are described more detail below, these illustrative embodiments example in the accompanying drawings Show.When describing embodiment, in order to provide the thorough understanding to the disclosure, it set forth many concrete details.But to this Field is not it is obvious to the skilled person that the present invention can be in the case where having the case where some or all of these details Implement.In other cases, it is not described in detail well-known feature and/or processing step, in order to avoid unnecessarily obscure this hair It is bright.The feature of each embodiment as described herein can be combined with each other, except separately having a special instruction.

In each embodiment, this disclosure relates to which honeycomb ceramics, can be constructed and be used as the honeycomb master comprising blocking The wall-flow filter of body, such as gasoline particles filter (GPF) or diesel particulate filter (DPF).In each embodiment In, it is preferable that it is designed relative to currently available particulate filter, filter disclosed herein can provide excellent in honeycomb ceramics The storage volume of different soot and/or cigarette ash or other inorganic particles, and it is further preferred that according to soot and/or cigarette The variation of ash loading and while keep relatively low cleaning pressure drop and relatively low pressure drop increase on the filter, provide Above-mentioned excellent storage volume.

Particulate filter (such as GPF or DPF) collects soot particles and cigarette ash, and can capture and be likely to be present in soot Or the inorganic material that may be peeled off from engine or exhaust component (such as manifold).Inorganic material is usually without regeneration and cigarette One combust of soot, therefore, inorganic substances can accumulate in particulate filter together with cigarette ash with the time.This accumulation may The pressure drop eventually led on honeycomb ceramics increases, and may be unacceptably high.It, can be by tearing open in order to mitigate this pressure rise Except and the more filter that renews or remove cigarette ash and inorganic material carry out particulate filter by clean filter Maintenance, this causes cost higher.

Therefore, according to one or more embodiments of the disclosure, honeycomb ceramics, which has high cigarette ash/inorganic matter storage, to be held Amount, to provide the longer time between each service intervals, and this is preferably limited according to soot and/or soot load change Change and caused by the increased loss of pressure drop.Moreover, one or more embodiments of the disclosure can provide manufacture benefit, this is Because existing relatively cheap extrusion die manufacturing technology can be used.For example, in one or more embodiments, it can With use pass completely through extrusion die exit face (for example, in a single direction, or even in 2 orthogonal directions) from side To the straight line die cuts of the other side.It is, for example, possible to use relatively cheap cutting wheel and/or wire rod electrical discharge machining (lines Material EDM) die head manufacturing technology, die head cost can be greatly reduced compared to other technologies (such as inserting milling EDM or ECM). In addition, one or more embodiments can have benefited from the improved structure of the honeycomb ceramics in green state and/or firing state Rigidity.

One or more embodiments of honeycomb ceramics include the more of the intersection in the matrix comprising constitutional repeating unit pattern Hole wall.Each constitutional repeating unit includes the first duct, the second duct, third duct and the 4th duct, wherein each duct exists It extends parallel to each other on axial direction from inlet face to exit face.Each duct is in the transverse plane orthogonal with axial direction There is quadrangular section in (hereinafter referred to " cross section ").The related duct of constitutional repeating unit is blocked to limit wherein Determine intake channel and exit passageway.Each constitutional repeating unit includes the first passage formed by the first duct, in cross section In include length L₁, width W₂With sectional area A₁, first passage includes the first side wall and second side orthogonal with the first side wall Wall.Each constitutional repeating unit includes the second channel formed by the second duct, and it includes length L in cross-section₂, it is wide Spend W₂With sectional area A₂, second channel and first passage share second sidewall.Each the third channel of " constitutional repeating unit " is by Three ducts are formed, and it includes length L in cross-section₁, width W₁With sectional area A₃, it includes third side walls, and with One channel shares the first side wall.Each the fourth lane of " constitutional repeating unit " is formed by the 4th duct, and it is in cross section In include length L₂, width W₁With sectional area A₄, and it shares the 4th side wall with second channel and shares with third channel Three side walls.First, second, and third channel includes intake channel, and fourth lane includes the exit passageway that cross section is rectangle, And wherein, meet W₁≥W₂And L₁≠L₂At least one of, and constitutional repeating unit includes quadrilateral periphery.Some In embodiment, W₁>W₂And L₂=L₁.In other embodiment, W₁>W₂And L₂≠L₁.In other embodiment, example Such as W₁>W₂And 0.5≤L₂/L₁≤1.25。W₁、W₂、L₁And L₂Other combination be also it is possible.

Complete description provides its of the embodiment of the constitutional repeating unit of one or more above-mentioned performance benefits herein His structure and microstructure properties.

As used herein, " honeycomb ceramics ", which is meant, is configured in tank or shell to be received into or for tank or shell Wall-flow honeycomb in body, it includes opening and interconnected porosity, the cell walls matrix of intersection, and include at least some stifled The exit passageway of the intake channel of plug and at least some blockings.

In the other embodiments of the disclosure, the micro particle filtering comprising honeycomb ceramics is provided as other aspect and feature Device, the exhaust system comprising particulate filter, for manufacturing the extrusion die of honeycomb ceramics of the present invention, and filtering particle and manufacture The method of honeycomb ceramics.

Herein, illustrative honeycomb ceramics, particulate filter have been described in further detail with reference to Figure 1A -10, comprising micro- The exhaust system of grain filter, for manufacturing the extrusion die of honeycomb ceramics as described herein, and filtering particle and manufacture honeycomb The method of body.

Figure 1A -1F illustrates respectively first illustrative embodiments of honeycomb ceramics 100 according to the present disclosure.Honeycomb Body 100 has the purposes for the filter medium being used as in particulate filter, and the particulate filter is used to flow from flowing, such as from interior Particle (such as soot and/or inorganic matter) is filtered in the engine exhaust stream of combustion engine (such as gas engine or diesel engine). Honeycomb ceramics 100 includes porous wall 102, intersects with each other (such as intersecting at a right angle) and forms multiple longitudinal directions parallel to each other and prolongs The duct stretched.Porous wall 102 may include opening, interconnected porosity, and porous wall 102 can be by ceramic or other are suitable Porous material be made, high temperature when use can be born, for example, the high temperature encountered during the hot recycling of honeycomb ceramics 100.Example Such as, the porous wall 102 of intersection can be made of ceramic materials, such as cordierite, silicon carbide (SiC), aluminium titanates, mullite, oxygen Change aluminium (Al₂O₃), silicon-aluminium-nitride-oxide (Al₆O₂N₆Si), the combination etc. of mullite, zeolite, above-mentioned substance.It can be used His suitable porous material, such as fused silica or porous metals or a combination thereof.

In the case where ceramics, wall 102 can be formed during extrusion process, wherein suitable batch mixtures [such as Inorganic and organic batch component and liquid carrier (such as water)] it is squeezed out by honeycomb extrusion die, it then dries and further burns System is to generate porous ceramic honeycombs (no tamper).It then, can restriction plug pattern blocking ceramic honeycomb as described herein Body, to generate honeycomb ceramics 100.Can the method as described in the US 6,673,300 of Allen et al. or by other methods come Complete blocking.In some embodiments, it can first block dry green honeycomb to be fired again, or carry out part burning System is blocked and is fired again.This document describes the various microstructure properties of the material of porous wall 102.

Honeycomb ceramics 100 is placed in outer radial periphery may include surface layer 103 (Fig. 1 E-1F), and the outer radial periphery, which is enclosed, to be defined The peripheral surface 100S of honeycomb ceramics 100.Surface layer 103 can squeeze out together with the extrusion of honeycomb substrate structure, or can squeeze (dry after or fire after) is applied to honeycomb ceramics after out, for example, in some embodiments, using the surface layer of rear application as being based on The surface layer putty of ceramics is applied on the outside (such as machined around) of ceramics or dry green body honeycomb. For example, surface layer 103 may include skin depth Ts (Fig. 1 E), around the substantially uniform radially around of honeycomb ceramics 100.Example Such as, skin depth Ts can be about 0.1mm to 100mm, or even 1mm to 10mm.Also other skin depths can be used Ts.Device and method for applying surface layer to product (such as honeycomb ceramics) are for example described in US 9,132,578.It can also make With other suitable methods for applying surface layer.In some embodiments as described herein, the porous wall 102 of intersection can be advantageous Ground extends continuously across honeycomb ceramics 100 between the various pieces on surface layer 103, so that for example obtaining reduces extrusion die into we The benefit in face.In other embodiments, the matrix of cell walls includes one or more constructions in identical honeycomb ceramics.

The outermost cross sectional shape of honeycomb ceramics 100 can be circle, ellipse, incubate shape or track type, but honeycomb ceramics 100 is not It is limited to these cross sectional shapes.Other cross sectional shapes, such as triangle or trilobal, square or rectangle can also be used.

Constitutional repeating unit includes multiple ducts, including the first duct 104, the second duct 106, third duct 108 and Four ducts 110, wherein other ducts of the cross sectional shape of the cross section at least some ducts and constitutional repeating unit 124 are not Together.In some embodiments, multiple duct 104-110 can by constituting in section there are two types of different types of hole road shape, Such as the combination of different quadrilateral hole road shapes, such as the combination of rectangular opening road shape and square hole road shape.Herein " rectangle " used means tool, and there are four the quadrangles on side and 90 degree of angle, wherein and first group of two sides have equal length, And second group of two sides have equal length, and its length is not identical as the length on first group of two sides.As herein Used " quadrangle " is meant and the quadrangle of only four straight flanges.In other embodiments, multiple duct 104-110 It can be by constituting in cross section there are four types of different types of hole road shape, such as the combination in various sizes of rectangle duct.First Duct 104, the second duct 106, third duct 108 and the 4th duct 110 all can be along from inlet faces 114 to exit face 116 axial axis 112 extends parallel to each other, wherein inlet face 114 and exit face 116 are general relative to each other, such as Fig. 1 C and 1D institute Show.The cross-sectional area of each duct 104-110 can be constant along its length.In addition, the lateral wall thickness of porous wall 102 Tw can be constant along the length of porous wall 102.

In one or more embodiments, the first duct 104, the second duct 106, third duct 108 and the 4th duct 110 with the blocking of plug pattern 118, and the surface of tamper and duct 104-110 together define intake channel 120 and outlet Channel 122.It is some blocked at or near exit face 116 in duct 104,106,108,110, but in inlet face 114 At or near be not blocked, and these ducts are defined herein as intake channel 120.Duct 104,106,108,110 In other ducts be blocked at or near inlet face 114, but be not blocked at or near exit face 116, and this Some holes road is defined herein as exit passageway 122.In the embodiment shown, the whole in constitutional repeating unit 124 Duct 104,106,108,110 can at least be blocked at one end or nearby, that is, whole ducts is blocked.So And in some embodiments, so that certain ducts is not blocked along its length, in honeycomb ceramics provide one or Multiple flowings by channel.

In embodiments, in honeycomb ceramics 100 and in constitutional repeating unit 124, the number of intake channel 120 can To be greater than the number of exit passageway 122.In embodiments, the number of intake channel 120 can be the number of exit passageway 122 Three times.The tamper 119 of plug pattern 118 can be formed by suitable plugging material, such as ceramic plugging material, including violet Green stone, aluminium titanates, mullite, silicon carbide, and/or the other materials of high temperature can be withstood, the high temperature is for example in bee The high temperature encountered during the hot recycling of nest body 100.It can be by suitable powder inorganic material and organic bond and liquid carrier Mixing, for example to generate plugging material.For example, suitable non-limiting plugging material and method be described in US 4,557,773, US 6,673,300, US7,744,669 and US 7,922,951.Tamper 119 can be neat with inlet face 114 and exit face 116 It is flat or can not be flush.Tamper 119 can be with filling channel width and height, and the axially blocking of axis 112 Depth can be for example, about 0.004 inch (0.10mm) to about 0.100 inch (2.54mm) or even about 0.004 inch (0.10mm) is to about 0.06 inch (1.52mm).Other plug depths can also be used.Tamper 119 may include opening interconnected pores Gap rate.

Referring now to Figure 1A -1B and Fig. 1 E-1F, the attached drawing shows the honeycomb ceramics comprising constitutional repeating unit 124 100, the constitutional repeating unit repeats in entire honeycomb ceramics 100.Constitutional repeating unit 124 as used herein is meant With three set with the single one in exit passageway 122 in the intake channel 120 of predetermined pattern arrangement, continuous repetition To form the structure of at least some honeycomb ceramics 100.As shown in the present embodiment, when from inlet face 114, Mei Gechong Complex structure unit 124 is made of one in exit passageway 122 with three in intake channel 120, and is had outside quadrangle All shapes (for example, the outer shape of constitutional repeating unit 124 is rectangle).Constitutional repeating unit 124 includes as shown in Figure 1B Construction and its mirror image.

In some embodiments, each constitutional repeating unit 124 is with the constitutional repeating unit 124 ' (In adjacent with other Marked in Figure 1A) it is the relationship that abuts directly against to provide, the constitutional repeating unit 124 ' and the constitutional repeating unit 124 It is essentially identical.In some regions of inlet face 114, constitutional repeating unit 124 can by with constitutional repeating unit 124 substantially Other identical adjacent constitutional repeating units 124 ' surround completely and adjoining.As shown in Figure 1A, constitutional repeating unit 124 is every Side can be abutted directly against by adjacent constitutional repeating unit 124 '.Some constitutional repeating units 124 near surface layer 103 can be with Adjoin one or more incomplete constitutional repeating units (it includes the entire infrastructure less than constitutional repeating unit 124).Such as answer Understand in other embodiments, there can be the duct of other constructions together with constitutional repeating unit 124 in honeycomb ceramics With the constitutional repeating unit in channel and other shapes.

In one or more embodiments, constitutional repeating unit 124 by arranged with limiting pattern first passage 125, Second channel 130, third channel 135 and fourth lane 140 are constituted, wherein each of channel 125-140 can at it Other each channels of the constitutional repeating unit 124 of (such as diagonal) are the relationship that abuts directly against to provide at each side or at angle. Referring now to Figure 1B, the cross section of the channel 125-140 of constitutional repeating unit 124 can be rectangle.In the illustrated embodiment, The cross-sectional shape of exit passageway 122 is rectangle (such as fourth lane 140).Other channels 125-135 is intake channel 120, And their cross-sectional shape is also possible to rectangle.Other embodiments as described herein may include that cross-sectional shape is square One or more combinations in the channel of shape and square.

It should therefore be understood that in some embodiments, the channel 125-140 in constitutional repeating unit 124 is respectively square Shape.In other embodiments, the first passage 125 in constitutional repeating unit and second channel 130 are rectangle.In other implementations In mode, first passage 125 and second channel 130 in constitutional repeating unit 124 are square.In some embodiments, Third channel 135 and fourth lane 140 in constitutional repeating unit 124 are rectangle.The channel of embodiment as described herein 125-140 respectively may include minor radius at one or more angles in its channel or chamfering or inclined-plane.

With reference to Figure 1B, constitutional repeating unit 124 includes the area of four channel 125-140, and including surrounding channel The half of the lateral wall thickness Tw of the porous wall 102 of the periphery of the cluster of 125-140.In other words, constitutional repeating unit 124 is equal to (L₁+L₂+2Tw)x(W₁+W₂+2Tw)。

It is the peripheral shape of quadrangle (such as rectangular or square) that constitutional repeating unit 124, which has cross section,.It repeats to tie Structure unit 124 includes first passage 125, can be formed by the first duct 104, and it includes length L in cross-section₁、 Width W₂With sectional area A₁.First passage 125 includes the first side wall 126 and the second sidewall 128 orthogonal with the first side wall 126. In the embodiment shown, first passage 125 includes intake channel 120, and in cross-section includes rectangular cross sectional shape, Wherein L₁>W₂.However, it should be apparent that in some embodiments, first passage 125 can have square section shape Shape (referring to Fig. 5, wherein W₂=L₁), or even rectangular section, wherein W₂>L₁, or even L₁>W₂。

The second channel 130 of constitutional repeating unit 124 can be formed by the second duct 106, and it is wrapped in cross-section L containing length₂, width W₂With the second sectional area A₂.Second channel 130 and first passage 125 share second sidewall 128.Shown in In embodiment, second channel 130 may include intake channel 120, and in cross-section include rectangular cross sectional shape, wherein L₂>W₂And L₁=L₂And A₁=A₂.However, in some embodiments, second channel 130 can have square cross-sectional shaped, Wherein W₂=L₂, or even rectangular section, wherein W₂>L₂, or even L₂>W₂。

The third channel 135 of constitutional repeating unit 124 can be formed by third duct 108, and it is wrapped in cross-section L containing length₁, width W₁With sectional area A₃.Third channel 135 includes third side wall 136, and shares first with first passage 125 Side wall 126.In the embodiment shown, third channel 135 includes intake channel 120, and in cross-section includes rectangle Cross sectional shape, wherein W₁>L₁。

The fourth lane 140 of constitutional repeating unit 124 can be formed by the 4th duct 110, and it is wrapped in cross-section L containing length₂, width W₁With sectional area A₄.Fourth lane 140 and second channel 130 share the 4th side wall 142, and logical with third Road 135 shares third side wall 136.In the embodiment shown, fourth lane 140 includes exit passageway 122, and transversal It include rectangular cross sectional shape, wherein W in face₁>L₂And A₄=A₃.However, in some embodiments, L₂>L₁And A₄>A₃.Optionally Ground, in some embodiments, L₂<L₁And A₄<A₃.Be described in more detail constitutional repeating unit 124 structure and micro- knot Structure attribute.

In some embodiments disclosed herein, cellular component 100A can by by multiple honeycomb ceramics 100B (such as With square or rectangular outer perimeter) it is bonded together generation, such as shown in Figure 1 G.Each honeycomb ceramics 100B may include multiple Constitutional repeating unit 124 repeats in honeycomb ceramics 100B as described herein.Suitable putty mixture can be used for bee The multiple portions of nest body 100B are bonded together.It is, for example, possible to use the putty mixtures as described in WO 2009/017642. The outer shape of cellular component 100A as shown in figure iG is square.However, it is possible to use other peripheral shapes, such as square Shape, circle, ellipse, oval, track type etc..Surface layer 103A can be applied around the periphery of cellular component 100A.

Fig. 4 A-4B instantiates the another embodiment of honeycomb ceramics 400 comprising identical with reference to described in Figure 1A -1F Constitutional repeating unit 124, that is, constitutional repeating unit 124 repeats at least part of honeycomb ceramics 400, but repetitive structure Unit 124 is orientated relative to some adjacent constitutional repeating units 124 ' being adjacent in decussate structure.For example, repetitive structure The pattern of unit includes that the constitutional repeating unit 124 being arranged with decussate structure, wherein first passage 125 and fourth lane 140 are total Use side wall.Particularly, constitutional repeating unit 124 is made to interlock, so that (hanging down as shown in the figure in identical exit passageway vertical row Directly, wherein third channel 135 and the long dimension orthogonal of fourth lane 140 alignment) in do not include direct neighbor repetitive structure list The exit passageway (such as fourth lane 140) of member 124 '.For example, as shown in Figure 4 A, the constitutional repeating unit 124 ' of direct neighbor It is shown as the column being deviated to the right from constitutional repeating unit 124.It has been surprisingly found that this friendship of constitutional repeating unit 124 Paramnesia, which is made, provides performance benefit in terms of significant lower pressure drop and improved filter efficiency compared to stacking construction, and can With increased intensity.In this staggered construction, the two sides of constitutional repeating unit 124 (such as left side as shown in the figure And right side) can be always by an adjacent constitutional repeating unit along its height (such as left and right side as shown in the figure) 124 ' abut directly against, and the other two sides (such as top side and bottom side as shown in the figure) of constitutional repeating unit 124 can be respective By (such as the two of two adjacent constitutional repeating units 124 ' above and lower section of two adjacent constitutional repeating units 124 ' A adjacent constitutional repeating unit 124 ') part abut directly against.

Fig. 5-7 instantiates other embodiment, wherein illustrate only each embodiment constitutional repeating unit 524, 624,724.Constitutional repeating unit 524,624 is in honeycomb with stack orientation as shown in Figure 1A or friendship as shown in Figure 4 A Any one of misorientation repeats.The embodiment of Fig. 7 can be provided with stacking construction.In stacking construction, repetitive structure The pattern of unit includes the constitutional repeating unit 124 being arranged with stacking construction, wherein first passage 125 and 140 nothing of fourth lane Share common sidewalls.Respectively include the honeycomb ceramics 500,600,700 of each constitutional repeating unit 524,624,724 by can with it is adjacent The constitutional repeating unit that constitutional repeating unit abuts directly against is constituted, the adjacent constitutional repeating unit and constitutional repeating unit 524,624,724 is identical.It abuts directly against as used in this article and means that there is no intermediate channels.In some embodiments, bee Nest body 500,600,700 is only by constitutional repeating unit 524,624,724 together with adjacent with the surface layer of honeycomb ceramics 500,600,700 Incomplete constitutional repeating unit is constituted.In other embodiments, honeycomb ceramics 500,600,700 can be by constitutional repeating unit 524, the other kinds of constitutional repeating unit of some combinations in 624,724 or channel are constituted.

With reference to Fig. 5, the constitutional repeating unit 524 of honeycomb ceramics 500 includes first passage 125 and second channel 130, they are Intake channel and include identical first shape, which is the cross-sectional shape of square.Third channel 135 and Four-way 140 includes respectively the second shape, is the cross-sectional shape of rectangle.Fourth lane 140 is exit passageway, and other are logical Road 125,130,135 is intake channel.Particularly, in this embodiment, A₄=A₃>A₂=A₁.Also, preferably In, L₁=L₂=W₂And W₂<W₁.Constitutional repeating unit 524 any one of can be following in honeycomb ceramics 500 construction arrangement: such as Stacking construction shown in figure 1A or decussate structure as shown in Figure 4 A.As should be understood, the combined shape of constitutional repeating unit 524 Shape and geometric dimension are that honeycomb ceramics 500 provides performance, shown according to the variation of soot load low cleaning pressure drop with And low pressure drop increases, in the state of clean conditions and/or load soot or cigarette ash so.Repetitive structure list is described below The specific structure size and other features and property of the embodiment of member 524.

For example, the following table 1 instantiates the performance of several representative configurations (embodiment 1-15 and 20-26) of honeycomb ceramics 500, institute The construction that honeycomb ceramics 500 includes constitutional repeating unit 524 shown in fig. 5 is stated, and is provided with decussate structure (such as Fig. 4 A).Separately Outside, Fig. 9 A and 9B instantiate with comparing embodiment (such as comparative example 1-3) draw together in the repetition knot comprising decussate structure Pressure drop performance in one illustrative embodiments of the honeycomb ceramics 500 of structure unit 524.

Do not include cigarette ash in Fig. 9 A, that is, includes the inventive embodiments 1 (example 1) of various soot loads (0-6g/L) Pressure drop performance figure instantiates the ash-free of this special tectonic of the honeycomb ceramics 500 including the constitutional repeating unit 524 that interlocks, load The pressure drop performance of soot is significantly better than any one of comparative example 1, comparative example 2 or comparative example 3, wherein (the ratio of comparing embodiment 1 Compared with example 1) it is ACT design, comparing embodiment 2 (comparative example 2) is the standard design that there is chessboard to block, and comparing embodiment 3 (comparative example 3) is high umber of feed inlet design.The following table 2 discloses comparative example 1-3.There is soot not only for all loads of example 1 The absolute magnitude of pressure drop (including cleaning pressure drop) of condition be lower, and the increased change rate of pressure drop (that is, the slope of pressure drop/ Soot load) it also reduces with soot load.

Fig. 9 B illustrates that the load of the example 1 comprising staggered constitutional repeating unit 524 has cigarette ash (such as 73.6g/L Cigarette ash) honeycomb ceramics 500, soot-loaded pressure drop is significant compared to comparing embodiment (comparative example 1-3) lower.In addition, ought be extremely When less compared with comparative example 1 and 2, when increasing to 6g/L from 0g/L with the soot load of soot, slope (the i.e. variation of pressure drop Rate) it is also lower.

The following table 2 shows the construction and property of comparative example 1-3.Comparative example 1 with US 6,696,132 Fig. 2 shown in and The honeycomb body structure, that is, be referred to as the channel design of asymmetric duct technology (ACT), wherein the area of intake channel is big In the area of exit passageway.Comparative example 2 be the honeycomb body structure of standard, wherein intake channel and exit passageway sectional dimension and Number is identical, for example, as shown in Fig. 1 of US 6,696,132.It is shown in the Fig. 4 of comparative example 3 with US 4,417,908 and described The increased number of channel design of import, that is, the constitutional repeating unit that honeycomb body structure is included all has square passageway, And intake channel is more than exit passageway.

Referring now to Figure 6, the figure shows the another embodiments of honeycomb ceramics 600.Fig. 6 individually shows repetition knot Structure unit 624.However, constitutional repeating unit 624 in honeycomb ceramics 600 can the stacking construction as shown in Figure 1A and 4A or staggeredly Any in construction arranges.The constitutional repeating unit 624 of honeycomb ceramics 600 includes first passage 125 and second channel 130, They are import and cross section is the cross sectional shape of rectangle.The cross section of third channel 135 and fourth lane 140 is also square Cross-sectional profile, and cross sectional shape having the same and area.Fourth lane 140 is exit passageway, wherein first passage 125, second channel 130 and third channel 135 are intake channels.

Particularly, in some embodiments of Fig. 6, A₄=A₃>A₂=A₁.Also, in such an embodiment, L₁= L₂, W₁>W₂,W₂>L₁And W₂>L₂.It is the shape and size of these combinations of constitutional repeating unit 624 as will be apparent Provide the performance of honeycomb ceramics 600, shown according to the variation of soot and/or soot load excellent cleaning pressure drop and Low pressure drop increases.The specific structure size and feature of constitutional repeating unit 624 is described below.In the similar embodiment party of Fig. 4 B In formula, provide as follows: L₁=L₂And W₁>W₂, but W₂<L₁, and W₂<L₂.In in addition optional embodiment, repetitive structure list Member 624 may include L₁=L₂And W₁=W₂, but wherein, W₂>L₁Or W₂<L₁.Embodiment 29 is all with rectangle, and L₁ =L₂And W₁=W₂。

Fig. 7 instantiates the another embodiment of honeycomb ceramics 700.Fig. 7 also individually shows constitutional repeating unit 724. In this embodiment, constitutional repeating unit 724 can be arranged in honeycomb ceramics 700 or with decussate structure shown in figure 1A. The constitutional repeating unit 724 of honeycomb ceramics 700 includes first passage 125 and second channel 130, their cross section is that rectangle is cut Face shape.However, in some embodiments, the cross section of first passage 125 and second channel 130 can have square shape Shape.The cross sectional shape of the cross section of third channel 135 and fourth lane 140 is rectangle.Fourth lane 140 is exit passageway, In, first passage 125, second channel 130 and third channel 135 are intake channels.Particularly, in this embodiment of Fig. 7 In, A₄>A₃>A₁>A₂.Also, in this embodiment, L₁≠L₂, W₁>W₂, W₁>L₁, W₁>L₂, W₂>L₁And W₂>L₂.Such as will it is aobvious and It being clear to, the combined shape and size of constitutional repeating unit 724 also provide the improvement performance of honeycomb ceramics 700, so that its Excellent cleaning pressure drop is shown according to the variation of soot and/or soot load and low pressure drop increases.Weight is described below The specific size and feature of the exemplary structure of complex structure unit 724.Optionally, in some embodiments, L₁≠L₂, W₁> W₂, W₁>L₁And W₁>L₂, but wherein, W₂<L₁And W₂<L₂。

Each embodiment of Figure 1A -1F, 4A-4B and 5-7 may include certain micro-structures and geometry property, they Excellent soot and soot load capacity and phase can be provided with the tectonic association of constitutional repeating unit 124,524,624,724 Combination to lower pressure drop performance, including relatively low cleaning pressure drop and with the variation of soot and/or soot load Relatively low pressure drop increase.For example, in some embodiments, after firing, the opening and interconnected porosity of porous wall 102 (%P) can be %P >=40%, %P >=45%, %P >=50%, %P >=60% or even %P >=65%.In some realities It applies in mode, the opening and interconnected porosity of the porous wall 102 of intersection can be 35%≤%P≤70%, or even 40%≤%P≤60%, or even 45%≤%P≤55%.Other %P values can also be used.Hole as described herein Rate (%P) is measured by mercury porosimetry mensuration.The honeycomb ceramics of each embodiment of Figure 1A -1F, 4A-4B and 5-7 100,400,500,600 and 700 may include inlet openings front face area (import OFA), be 38%≤import OFA≤ 62%, or even 44%≤import OFA≤55%.

In some embodiments, after firing, the lateral wall thickness Tw that porous wall 102 may include is the English of Tw >=0.004 Very little (0.102mm), Tw >=0.006 inch (0.150mm), Tw >=0.008 inch (0.203mm) or even Tw >=0.010 Inch (0.254mm).In some embodiments, Tw≤0.014 inch (0.356mm), Tw≤0.012 inch (0.305mm), Or even Tw≤0.010 inch (0.254mm).For example, in one or more embodiments, 0.004 inch (0.102mm)≤Tw≤0.014 inch (0.356mm), or even 0.006 inch of (0.150mm)≤Tw≤0.010 inch (0.254mm).It can also be using the other values of lateral wall thickness Tw.

In some embodiments, after firing, porous wall 102 be may include following mean pore sizes (MPD): 10 μm≤MPD ≤ 16 μm, or even 11 μm≤MPD≤15 μm.It is open, the range Db of the pore size distribution of interconnected porosity can be Db ≤ 1.5, or even Db≤1.0, wherein Db=((D₉₀-D₁₀)/D₅₀), wherein D₉₀Be 90% hole have it is equal or smaller The equivalent spherical diameter of the pore size distribution of diameter and 10% porous wall 102 of the hole with larger diameter, and D₁₀It is 10% hole With equal or smaller diameter, 90% hole has the equivalent spherical diameter in the pore size distribution of larger diameter.Mean pore sizes (MPD) it can for example be measured by mercury porosimetry with the range Db of pore size distribution.

In some embodiments, the cell densities (CD) of honeycomb ceramics 400,500,600,700 can be 10 duct/English It is very little²(1.55 duct/cm²)≤CD≤400 hole track per inch²(62 duct/cm²), or even 50 hole track per inches² (7.75 duct/cm²)≤CD≤375 hole track per inch²(58 duct/cm²), or even 225 hole track per inches² (35 duct/cm²)≤CD≤375 hole track per inch²(58 duct/cm²), and can be CD >=150 duct/English It is very little²(23 duct/cm²), or even CD >=200 hole track per inch²(31 duct/cm²).Other holes can also be used Track density.%P, Tw, Db, MPD and CD described above can form any combination each other in any combination, and can be with this The combination of constitutional repeating unit described in text.

For each embodiment of Figure 1A -1F, 4A-4B and 5-7, area A can be adjusted according to the relationship hereafter limited₁ To A₄Size, wherein in each embodiment, channel 125-140 includes the section of quadrangle form, and fourth lane 140 be exit passageway, and cross section has quadrangle and is the cross sectional shape of rectangle.In other embodiments, repetitive structure The quadrangular cross-section shape of unit 524,724 may include some rectangular channels and some square passageways.In addition, in each reality It applies in mode, constitutional repeating unit 124,524,624,724 has quadrilateral periphery shape, such as rectangle or even square Shape peripheral shape.

Ratio A₃/A₁

The structure of constitutional repeating unit 124,524,624,724 is selected, to provide excellent soot bearing capacity, Low cleaning pressure drop and the increased combination of low pressure drop changed according to soot and/or soot load.More specifically, at one Or in multiple embodiments, the geometry of constitutional repeating unit 124,524,624,724 may include A₄≥A₃>A₂≥A₁.Separately Outside, in some embodiments, it is to make A that the size of first passage 125 and third channel 135 is adjustable₃/A₁Ratio can be with It is A₃/A₁>=1.2, or even A₃/A₁>=1.5, or even A₃/A₁>=2.0, or even A₃/A₁>=2.5, or Even A₃/A₁≥4.0.In some embodiments, A₃/A₁Ratio can even is that A₃/A₁≤10.In some embodiments In, A₃/A₁Ratio may include A₃/A₁≤ 4.0, or even A₃/A₁≤2.5.In one or more embodiments, A₃/A₁Ratio for example can be 1.2≤A₃/A₁≤ 10, or even 1.2≤A₃/A₁≤ 4.0, or even 1.2≤ A₃/A₁≤2.5.For example, A₃It can be 0.00239 inch²(1.54mm²)≤A₃≤ 0.01990 inch²(12.8mm²), A₁It can be with It is 0.00150 inch²(0.968mm²)≤A₁≤ 0.00398 inch²(2.57mm²).In some embodiments, repetitive structure list The structure of member 124,524,624,724 includes A₃/A₁≤ 10 and OFA > 38%, or even A₃/A₁≤ 10 and OFA > 44%.

Ratio A₄/A₂

Similarly, for the disclosed embodiment of Figure 1A -1F, 4A-4B and 5-7, constitutional repeating unit 124,524, 624,724 geometry may include ratio A₄/A₂>=1.2, or even A₄/A₂>=1.5, or even A₄/A₂≥ 2.0, or even A₄/A₂>=2.5, or even A₄/A₂≥4.0.In some embodiments, A₄/A₂Ratio can be with It is A₄/A₂≤10.In some embodiments, for example, A₄/A₂Ratio can be A₄/A₂≤ 4.0, or even A₄/A₂≤ 2.5.In some embodiments, A₄/A₂Ratio can be 1.2≤A₄/A₂≤ 10, or even 1.2≤A₄/A₂≤ 4.0, Or even 1.2≤A₄/A₂≤2.5.For example, A₄It can be 0.00239 inch²(1.54mm²)≤A₄≤ 0.01990 inch² (12.8mm²), and A₂It can be 0.00150 inch²(0.97mm²)≤A₂≤ 0.01990 inch²(12.8mm²)。

As shown in the embodiment of Figure 1A -1F, 4A-4B and Figures 5 and 6, L₁=L₂And W₁≠W₂.It is deposited in shown construction In L₁=L₂Can have following advantage: due to can on a direction of extrusion die (vertically as shown in the figure) (such as along Short transverse) the appropriate cutting at equal intervals on a whole direction is realized for example, by wire rod EDM or saw cut, therefore be easy to Manufacture this extrusion die.In addition, porous wall 102 can be from surface layer 103 in honeycomb ceramics 100,400,500,600,700 One part extends to another part on surface layer 103, therefore all intersection porous walls 102 were extended continuously import with straight line Face 114 and exit face 116.On another orthogonal direction (such as in horizontal direction as shown in the figure), it may be implemented non-etc. The appropriate cutting of spacing, but be also for example by carrying out wire rod EDM or sawing on the entire width of extrusion die with straight line It cuts to carry out, to obtain the intersection porous wall 102 being extended continuously on the width of honeycomb ceramics 100,400,500,600,700 Horizontal wall.

Ratio W₁/W₂

As shown in the embodiment of Figure 1A-1F, 4A-4B and Fig. 5-7, each constitutional repeating unit 124-724 be may include W₁/W₂>=1.2, or even W₁/W₂>=1.5, or even W₁/W₂>=2.0, or even W₁/W₂>=3.0, or very To being W₁/W₂>=4.0 geometry.In some embodiments, W₁/W₂≤ 10, or even W₁/W₂≤ 4.0, or very To being W₁/W₂≤2.5.In some embodiments, for example, W₁/W₂Ratio can be 1.2≤W₁/W₂≤ 10, or even 1.2≤W₁/W₂≤ 4.0, or even 1.2≤W₁/W₂≤2.5.For example, W₂It can be 0.035 inch of (0.883mm)≤W₂≤ 0.069 inch (1.75mm), and W₁It can be 0.048 inch of (1.22mm)≤W₁≤ 0.196 inch (4.98mm).Some In embodiment, 1.2≤W₁/L₂≤ 10 and 1.2≤W₁/L₁≤ 10, or even 1.2≤W₁/L₂≤ 4.0 and 1.2≤W₁/L₁ ≤ 4.0, or even 1.2≤W₁/L₂≤ 2.5 and 1.2≤W₁/L₁≤2.5。

A particularly effective example of any construction in comprising constitutional repeating unit 124,524,624 or 724 In, the wall thickness Tw for the intersection porous wall 102 that honeycomb includes is 0.006 inch of (0.152mm)≤Tw≤0.010 inch (0.254mm), the open porosity (%P) of intersection porous wall 102 are 40%≤P%≤60%, the mean pore sizes of porous wall 102 It (MPS) is 10 microns≤MPS≤16 micron, inlet openings front face area (import OFA) is 38%≤import OFA≤62%, and And W₁/W₂Ratio be 1.2≤W₁/W₂≤2.5.It also may include other geometrical characteristics, such as L₁=L₂, L₂>L₁, or even It is L₂<L₁。

As shown in the embodiment of Figure 1A-1F, 4A-4B and Fig. 5-7, each constitutional repeating unit 124-724 be can wrap Include following geometry, wherein the sectional area of fourth lane 140 (including outlet duct) is divided by constitutional repeating unit 124-724 The area fraction of sectional area of all channel 125-140 can be between 0.27 to 0.46.

In the certain embodiments with constitutional repeating unit 124,624, such as Figure 1A -1F, Fig. 4 A-4B and Fig. 6 institute Those of show, first passage 125 and second channel 130 include identical first rectangular cross-sectional shape, third channel 135 and the Four-way 140 includes identical second rectangular shape.Also, in these embodiments, first passage 125, second channel 130 It is intake channel with third channel 135, and fourth lane 140 is exit passageway.Specifically, in these embodiments, each The area in channel can be sized according to following relationship: A₄=A₃>A₂=A₁。

In the other embodiment with constitutional repeating unit 724, such as shown in Fig. 7, first passage 125 and second Channel 130 includes the different quadrangular cross section shape of size, and third channel 135 and fourth lane 140 also include that size is different Quadrangular cross section shape.Specifically, in one embodiment, four all channel 125-140 can have rectangle Cross-sectional shape.Also, in these embodiments, first passage 125, second channel 130 and third channel 135 are that import is logical Road, and fourth lane 140 is exit passageway.Specifically, in some embodiments, the area in each channel can be according to following Relationship is sized: A₄≠A₃>A₂≠A₁.In the embodiment of Fig. 7, L₂/L₁>=1.2, or even L₂/L₁>=1.5, Or even L₂/L₁>=2.0, or even L₂/L₁>=2.5 or even L₂/L₁≥4.0.In some embodiments, L₂/L₁≤ 10, L₂/L₁≤ 4.0, or even L₂/L₁≤2.5.In the embodiment of some Fig. 7, L₂/L₁It can be 1.2≤ L₂/L₁≤ 10, or even 1.2≤L₂/L₁≤ 4.0, or even 1.2≤L₂/L₁≤2.5。

Referring now to Figure 5, the figure shows a particularly effective implementations of the constitutional repeating unit 524 of honeycomb ceramics 500 Mode.In the embodiment shown, as previously mentioned, the constitutional repeating unit 524 of honeycomb ceramics 500 includes first passage 125, the Two channels 130, third channel 135 and fourth lane 140, but wherein, the area in each channel can according to following relationship come It is sized: A₄=A₃>A₁=A₂.In addition, first passage 125 and second channel 130 include identical first square cross section Shape and they be intake channel, third channel 135 is intake channel, and fourth lane 140 is exit passageway, and third is logical Road 135 and fourth lane 140 include identical second rectangular cross-sectional shape.

Particularly, for the embodiment of Fig. 5, constitutional repeating unit 524 may include L₁=L₂And W₁≠W₂Geometry knot Structure.Third channel 135 and fourth lane 14 respectively include W₁>L₁And W₁>L₂Rectangular shape.Particularly, for the embodiment party Formula, W₁>W₂.For the embodiment, A₃/A₁Ratio can be A₃/A₁>=1.2, or even A₃/A₁>=1.5, or very To being A₃/A₁>=2.0, or even A₃/A₁>=2.5, or even A₃/A₁≥4.0.For the embodiment, A₃/A₁'s Ratio can be A₃/A₁≤ 10, or even A₃/A₁≤ 4.0, and can be A in some embodiments₃/A₁≤2.5。 For the embodiment, A₃/A₁It can be 1.2≤A₃/A₁≤ 10, or even 1.2≤A₃/A₁≤ 4.0, or even one It is 1.2≤A in a little embodiments₃/A₁≤2.5。

Embodiment

The honeycomb ceramics 400,500,600 of honeycomb shown in the embodiment comprising Fig. 4 A-7 is provided in the following table 1 With 700 embodiment.A₁To A₃It is the cross-sectional area of corresponding intake channel, and A₄It is the cross-sectional area in rectangular outlet channel.Separately Outside, the following table 1 show based on for each embodiment modelling estimation performance, including with comparing embodiment 1-3 (comparative example Comparable situation 1-3).Particularly, provide it is various under the conditions of pressure drop (Δ P) performance (compare compared to each comparing embodiment Example 1-3) percentage improve (%IMP).

Table 1 --- invention honeycomb ceramics embodiment (embodiment 1 to embodiment 5)

Table 1 --- continuous (embodiment 6 to embodiment 10)

Table 1 --- continuous (embodiment 11 to embodiment 15)

Table 1 --- continuous (embodiment 16 to embodiment 20)

Table 1 --- continuous (embodiment 21 to embodiment 25)

Table 1 --- continuous (embodiment 26 to embodiment 27)

Table 2 --- comparing embodiment (comparative example 1 to comparative example 3)

2 (Continued) of table

Embodiment 1-15 and embodiment 20-26 and 28 show L₁=L₂And W₁>W₂Embodiment, wherein embodiment 28 All rectangles.Embodiment 16-19 and embodiment 27 show L₁≠L₂Embodiment.Embodiment 16-19 shows L₁≠L₂ And W₁>W₂Combination embodiment.Embodiment 27 shows L₁≠L₂And W₁=W₂Embodiment.Specifically, in embodiment 27, Construction includes L₁<L₂.Embodiment 29 shows L₁=L₂And W₁=W₂, but W₁≠L₂Embodiment.Specifically, in embodiment 29 In, W₁>L₂.Optionally, however, constitutional repeating unit may include L₁=L₂And W₁=W₂, but W₁<L₂。

Referring now to Figure 2, the figure shows the micro particle filterings comprising honeycomb ceramics 100 (or optionally, honeycomb ceramics 400-700) Device 200.In the embodiment shown, honeycomb ceramics 100 is contained in tank 205, the tank 205 be, for example, metal shell or other Restrictive.Tank 205 can include: the first end cover comprising import 207 is configured to receive containing soot and/or nothing The engine exhaust 211 of machine particle；Second end cover comprising outlet 209 is configured to gas stream of the discharge by filtering, Wherein, the particle 213 (such as soot and/or inorganic substances) of the big percentage in engine exhaust (for example, about 99% or bigger) Removed/filtering, and be transported in the intake channel 120 and opening interconnected pores of honeycomb ceramics 100.Honeycomb ceramics 100 Surface layer 103 can have the component 215 being in contact with it, such as high temperature insulation material, to buffer honeycomb ceramics 100 from impacting and answering Power influences.Any suitable constructions of component 215, such as the construction of one-piece construction or two or more layers can be used.Bee Nest body 100 and component 215 can be contained in tank 205 by any suitable means, such as by being pooled in central body, Then can be formed in one or more of first end cover and second end cover is firm (such as welding) to central body into Mouth 207 and outlet 209.Other two-piece constructions or clam shell construction of tank 205 can optionally be used.

Fig. 3 instantiates the exhaust system 300 for being connected to engine 317 (such as gasoline engine or diesel engine).Row Gas system 300 may include the manifold 319 for being connected to the exhaust port of engine 317, be configured to manifold 319 with The first collecting pipe 321 connected between particulate filter 200 contains honeycomb ceramics 100 in the particulate filter 200.Connection It can be any suitable clamping bracket or other attachment mechanisms.In some embodiments, the first collecting pipe 321 can be with discrimination Pipe 319 is integrally formed.In some embodiments, particulate filter 200 can be directly connected to manifold without intermediate member. Exhaust system 300 can also include the second collecting pipe 323, be connected to particulate filter 200 and second exhaust component 327.The Two exhaust components 327 for example can be muffler, catalytic converter or even the second particulate filter.(the truncation of tail pipe 329 Show) or other pipelines or component may be coupled to second exhaust component 327.Other exhaust system components may include example Such as lambda sensor, urea injection port (not shown).Engine 317 may include a particulate filter 200, be used to send out Each inblock cylinder (the side group of cylinder) of motivation 317, or optionally, the first collecting pipe 321 can be Y tube, be used to receive Collect the soot from each inblock cylinder and soot is directed to particulate filter 200.Using including embodiment described herein The particulate filter 200 of honeycomb ceramics 100 interval time between regeneration event can be made elongated, this is because particulate filter 200 have relatively large cigarette ash and soot load ability.In addition, the honeycomb ceramics 100 in exhaust system 300 applied it is opposite Lower back pressure can be such that exhaust stream flows freely and minimize the power decline of engine 317 substantially.Some In embodiment, the exhaust system 300 comprising honeycomb ceramics 100 has preferably provided extremely low cleaning pressure drop, low load soot and The pressure drop of soot loaded, and the low pressure drop changed with soot and/or soot load are advanced the speed.Exhaust system 300 It is described as comprising the honeycomb ceramics 100 shown and described with reference to Figure 1A -1F.However, other honeycomb ceramics 400,500,600 and 700 can To replace honeycomb ceramics 100 in exhaust system 300.

Referring now to Fig. 8 A-8F, attached drawing is provided according to embodiment of the present disclosure, is configured to manufacture honeycomb ceramics The honeycomb extrusion die 800 of 100-700.Honeycomb ceramics 100-700 can pass through following formation: batch mixtures being made to be extruded through bee Nest extrusion die 800 is to generate green honeycomb, and the batch mixtures are for example in US3,885,977, US 5,332,703, US 6,391,813, described in US 7,017,278, US 8,974,724, WO2014/046912 and WO2008/066765.Then may be used To dry green honeycomb, for example, such as in US 9,038,284, US 9,335,093, US 7,596,885 and US 6,259, Described in 078.Then green honeycomb, such as such as US 9,452,578, US 9,446,560, US 9,005 can be fired, 517,8 US, 974,724, US 6,541,407 and US 6, described in 221,308, to form honeycomb ceramics 100-700, have Porous ceramic walls honeycomb comprising geometry as described herein (or structure) and micro-structure.

Honeycomb extrusion die 800 includes die body 839, is configured to receive the die head of extrudable batch mixtures Inlet face 842, and the die head exit face 844 opposite with die head inlet face 842, the die head exit face 844 be configured to Batch of material is discharged in the form of green honeycomb with honeycomb.Extrusion die 800 may be coupled to the extruder for accommodating batch of material (not shown), such as plunger-type extruder or screw extruder (such as double screw extruder), wherein extruder forces batch of material pressing Pass through extrusion die 800 under power.

Honeycomb extrusion die 800 includes the multiple feed openings 845 extended in die body 839 from die head inlet face 842 (being marked), and the array of slit 848 (being marked) of intersection extend to die body from die head exit face 844 In 839, and it is connect with multiple feed openings 845.Feed opening 845 supplies batch of material to the array of slit 848.The slit 848 of intersection Array includes: to pass completely through the first slit 850 (being marked) of the extension of die head exit face 844 (for example, as schemed institute with straight line Show and extend vertically) and the second slit 852, can be orthogonal with the first slit 850 and die head is also passed completely through with straight line go out Mouth face 844 extends (for example, horizontal extension as shown in the figure).The array of the slit 848 of intersection forms the battle array in unit die head duct 824 Column, at least some upper repetitions in die head exit face 844 can cover substantially all of mould in some embodiments Head exit face 844.As shown, for example, unit die head duct 824 can be arranged in the horizontal direction with syntople side by side, And it overlies one another in vertical direction.Honeycomb extrusion die 800 may include the part 800S to form surface layer comprising be formed The cover 849 (for example, endless shaper article) on surface layer, the cover 849 on the formation surface layer and the feed opening 845S for forming surface layer have a common boundary to squeeze It is formed in the green honeycomb by extrusion formed during method out and squeezes out surface layer.

Each unit die head duct 824 includes the first part of the die head 825, the second part of the die head 830, third part of the die head 835 and the 4th part of the die head 840, they can be arranged as shown in Figure 8 C.Each part of the die head 825-840 includes that die head core (divides Wei P1-P4) and the width Ws of slit of array of the slit 848 in the intersection of periphery (be a half width on every side Ws).First part of the die head 825 includes length L in cross section_1’, width W_2’With sectional area A_1’.Second part of the die head 830 is in section In include length L_2’, width W_2’With sectional area A_2’.Third part of the die head 835 includes length L in cross section_1’, width W_1’With cut Area A_3’, and the 4th part of the die head 840 includes length L in cross section_2’, width W_1’With sectional area A_4’, wherein the 4th die section Part 840 includes rectangular cross sectional shape.Section passes through core (P1-P4) in the plane for being parallel to die head exit face 844.

According to embodiment, part of the die head 825-840 may be constructed such that the first construction or the second construction, that is, can be to mould The construction of head part 825-840 is selected to provide at least one of the first construction or the second construction, wherein the first construction It is:

W_1’>W_2’And L_1’=L_2’And A_4’=A_3’>A_2’=A_1’

Second construction is selected from one of following:

L_1’≠L_2’And A_4’>A_3’>A_2’<A_1’,

L_1’≠L_2’And A_4’>A_2’>A_3’<A_1’,

L_1’≠L_2’And A_3’>A_4’>A_1’<A_2’, or

L_1’≠L_2’And W_1’=W_2’And A_4’=A_2’>A_3’=A_1’。

In one or more embodiments of the first construction, unit die head duct 824 includes the first configuration and structure, Middle W_1’>W_2’And L_1’=L_2’, third part of the die head 835 and the 4th part of the die head 840 include identical quadrangle (such as rectangle) shape Shape, and the first part of the die head 825 and the second part of the die head 830 include identical quadrangle form, and unit die head duct 824 has There is the peripheral shape for being similarly quadrangle (such as rectangular or square).

One or more embodiments of the first combination include unit die head duct 824, and it includes part of the die head 825- 840 area and following relationship: A_4’=A_3’>A_2’=A_1’Relevant structure.Particularly, ratio A_3’/A_1’It can be A_3’/A_1’≥ 1.2, or even A_3’/A_1’>=1.5, or even A_3’/A_1’>=2.0, or even A_3’/A_1’>=2.5, or even It is A_3’/A_1’≥4.0.In some embodiments, A_3’/A_1’It can be 1.2≤A_3’/A_1’≤ 10, or even 1.2≤A_3’/ A_1’≤ 4.0, or even 1.2≤A_3’/A_1’≤2.5.Similarly, ratio A_4’/A_2’It can be A_4’/A_2’>=1.2, or even It is A_4’/A_2’>=1.5, or even A_4’/A_2’>=2.0, or even A_4’/A_2’>=2.5, or even A_4’/A_2’≥ 4.0.In some embodiments, A_4’/A_2’It can be 1.2≤A_4’/A_2’≤ 10, or even 1.2≤A_4’/A_2’≤ 4.0, or Person even 1.2≤A_4’/A_2’≤2.5。

In second of combination, L_1’≠L_2’.In some embodiments that second is combined, unit die head duct 824 can With L_2’>L_1’.In second of combined further embodiments, unit die head duct 824 can have L_1’>L_2’。

(referring to embodiment 19) in first embodiment that second is combined, honeycomb extrusion die 800 includes unit Die head duct 824 is chosen such that L to it_2’>L_1’And W_1’>W_2’, to make A_4’>A_3’>A_2’<A_1’.In first embodiment party In formula, unit die head duct 824 can have W_2’>L_1’。

In second embodiment that second is combined, honeycomb extrusion die 800 includes unit die head duct 824, right It is chosen such that L_2’>L_1’And W_1’>W_2’, to make A_4’>A_2’>A_3’<A_1’.In the second embodiment, unit die holes Road 824 can have W_2’<L_1’。

(referring to embodiment 16 to embodiment 18) in second of combined third embodiment, honeycomb extrusion die 800 include unit die head duct 824, is chosen such that L to it_1’>L_2’And W_1’>W_2’, and A_3’>A_4’>A_1’<A_2’。

(referring to embodiment 27) in the 4th embodiment that second is combined, honeycomb extrusion die 800 includes unit Die head duct 824 is chosen such that L to it_2’>L_1’And W_1’=W_2’, and unit die head duct 824 is chosen such that A_4’=A_2’>A_3’=A_1’。

In W_1’>W_2’Embodiment in, ratio W_1’/W_2’It can be 1.2≤W_1’/W_2’≤ 4.0, or even 1.2≤ W_1’/W_2’≤2.5.In L_2’>L_1’Embodiment in, ratio L_2’/L_1’Ratio can be L_2’/L_1’>=1.2, or even L_2’/L_1’>=1.5, or even L_2’/L_1’>=2.0, or even L_2’/L_1’>=2.5, or even L_2’/L_1’>=4.0, Or even L_2’/L_1’≥10.In some embodiments, L_2’/L_1’It can be 1.2≤L_2’/L_1’≤ 10, or even 1.2≤L_2’/L_1’≤ 4.0, or even 1.2≤L_2’/L_1’≤2.5。

In L_2’<L_1’Embodiment in, ratio L_2’/L_1’Ratio can be 0.8 >=L_2’/L_1’>=0.1 or L_2’/L_1’ It can even is that 0.8 >=L_2’/L_1’>=0.4, or in some embodiments, L_2’/L_1’It can even is that 0.8 >=L_2’/L_1’≥ 0.65.However, the 4th part of the die head 840 is always rectangular section.In some embodiments, L_2’/L_1’It can be L_2’/L_1’≥ 1.0.In other embodiment, 0.5≤L_2’/L_1’≤1.25。

Fig. 8 D-8F instantiates several embodiments of honeycomb extrusion die 800,800A, 800B comprising different chargings Sectional hole patterns (feed opening 845 is shown as circle of dotted line, and slit is shown as solid line).Fig. 8 D is instantiated includes in each intersection of slit Feed opening 845 and also include feed opening in the centre of each intersection of biggish die head core P3, the P4 in unit die head duct 824 845 first embodiment.This feed opening construction can be used for ratio W_2’/W_1’Relatively large (such as W_2’/W_1’It is greater than 2.0) embodiment of honeycomb extrusion die 800.

Fig. 8 E instantiates second embodiment of honeycomb extrusion die 800A, wherein in two directions, in slit It include feed opening 845 at an intersection location, to include feed opening 845 on each side of die unit duct 824A, but Being does not include feed opening 845 on angle.The embodiment of Fig. 8 E of honeycomb extrusion die 800A can be used for ratio W_2’/W_1’Phase To smaller (such as W_2’/W_1’Less than or equal to about embodiment 1.5).

Fig. 8 F instantiates the third embodiment of honeycomb extrusion die 800B, wherein in horizontal narrow slit every one It include feed opening 845 at horizontal intersection location and in upright position, so that at the center C of each die unit duct 824B Intersection location from four direction feed batch of material.The embodiment of Fig. 8 E can be used for ratio W_2’/W_1’Relatively small (such as W_2’/ W_1’Less than or equal to about embodiment 2.0).

Figure 10 describes the method 1000 that particle is filtered according to one or more embodiments.This method 1000 is wrapped It includes: in 1002, providing honeycomb ceramics as described herein (such as honeycomb ceramics 100,400,500,600 or 700), and wrapped It is contained in particulate filter (such as particulate filter 200), and in 1004, soot is captured in honeycomb ceramics.

Above description discloses the illustrative embodiments of the disclosure.It is above-disclosed within the scope of the disclosure for falling into The change of equipment, system and method will be apparent.For example, any combination of microstructure parameters disclosed herein can be used In honeycomb embodiment disclosed herein.For example, disclosed parameter %P, MPS, Tw, Db and CD can with it is any disclosed Constitutional repeating unit 124-724 combined application.Therefore, although the disclosure includes certain illustrative embodiments, it should be appreciated that Other embodiments can be fallen in the scope of the present disclosure limited such as the appended claims.

Claims

1. a kind of honeycomb ceramics comprising:

The porous wall of intersection in matrix comprising constitutional repeating unit pattern, wherein each constitutional repeating unit includes first Duct, the second duct, third duct and the 4th duct, wherein the first duct, the second duct, third duct and the 4th duct are equal It extends parallel to each other on the axial direction from inlet face to exit face, and has in the transverse plane orthogonal with axial direction There is quadrangular section, and they are blocked and clog to limit intake channel and exit passageway in constitutional repeating unit, wherein each A constitutional repeating unit includes:

The first passage limited by the first duct includes length L in cross-section₁, width W₂With sectional area A₁, first passage With the first side wall and the second sidewall orthogonal with the first side wall；

The second channel limited by the second duct includes length L in cross-section₂, width W₂With sectional area A₂, and second Channel and first passage share second sidewall；

The third channel limited by third duct includes length L in cross-section₁, width W₁With sectional area A₃, the third Channel include third side wall and its with first passage share the first side wall；With

The fourth lane limited by the 4th duct includes length L in cross-section₂, width W₁With sectional area A₄, and its with Second channel shares the 4th side wall and shares third side wall with third channel, and

Wherein, first passage, second channel and third channel are intake channels, and fourth lane is that cross section has rectangular shape Exit passageway, and

Meet W₁≥W₂And L₁≠L₂At least one of in, and constitutional repeating unit includes quadrilateral periphery.

2. honeycomb ceramics as described in claim 1, wherein the cross section in each duct in constitutional repeating unit is rectangle.

3. honeycomb ceramics as described in claim 1, wherein the cross section in the first duct and the second duct in constitutional repeating unit For rectangle.

4. honeycomb ceramics as described in claim 1, wherein the cross section in the first duct and the second duct in constitutional repeating unit It is square.

5. honeycomb ceramics as described in claim 1, wherein the cross section in third duct and the 4th duct in constitutional repeating unit For rectangle.

6. honeycomb ceramics as described in claim 1, wherein the pattern of constitutional repeating unit includes the repetition being arranged with stacking construction Structural unit, wherein first passage and fourth lane not common wall.

7. honeycomb ceramics as described in claim 1, wherein the pattern of constitutional repeating unit includes the repetition being arranged with decussate structure Structural unit, wherein first passage and fourth lane common wall.

8. honeycomb ceramics as described in claim 1, wherein all porous walls are extended continuously on inlet face.

9. honeycomb ceramics as described in claim 1, it includes the surface layer that the outer radial periphery in honeycomb ceramics is placed, and it is all more Hole wall is extended continuously between each section on surface layer along honeycomb ceramics.

10. honeycomb ceramics as described in claim 1, it includes: A₄≥A₃>A₂≥A₁。

11. honeycomb ceramics as claimed in claim 10, it includes: A₃/A₁≥1.2。

12. honeycomb ceramics as claimed in claim 10, it includes: A₃/A₁≤ 10 and import OFA > 38%, wherein import OFA is Inlet openings front face area.

13. honeycomb ceramics as claimed in claim 10, wherein A₃/A₁≤4.0。

14. honeycomb ceramics as claimed in claim 10, wherein A₃/A₁≤2.5。

15. honeycomb ceramics as claimed in claim 10, wherein 1.2≤A₃/A₁≤10。

16. honeycomb ceramics as claimed in claim 10, wherein 1.2≤A₃/A₁≤4.0。

17. honeycomb ceramics as claimed in claim 10, wherein 1.2≤A₃/A₁≤2.5。

18. honeycomb ceramics as claimed in claim 10, in which:

1.86mm²≤A₃≤12.8mm², and

0.97mm²≤A₁≤2.57mm²。

19. honeycomb ceramics as claimed in claim 10, wherein A₄/A₂≥1.2。

20. honeycomb ceramics as claimed in claim 10, wherein A₄/A₂≤2.5。

21. honeycomb ceramics as claimed in claim 10, wherein 1.2≤A₄/A₂≤10。

22. honeycomb ceramics as claimed in claim 10, wherein 1.2≤A₄/A₂≤2.5。

23. honeycomb ceramics as claimed in claim 10, it includes:

0.97mm²≤A₂≤2.57mm², and

A₄It is 1.86mm²≤A₄≤12.8mm²。

24. honeycomb ceramics as claimed in claim 10, wherein W₁/W₂≥1.2。

25. honeycomb ceramics as claimed in claim 10, it includes W₁/W₂≤10.0。

26. honeycomb ceramics as claimed in claim 10, it includes W₁/W₂≤4.0。

27. honeycomb ceramics as claimed in claim 10, it includes 1.2≤W₁/W₂≤10。

28. honeycomb ceramics as claimed in claim 10, it includes 1.2≤W₁/W₂≤2.5。

29. honeycomb ceramics as claimed in claim 10, wherein 1.2≤W₁/L₁≤ 10 and 1.2≤W₁/L₂≤10。

30. honeycomb ceramics as claimed in claim 10, wherein 1.2≤W₁/L₁≤ 4.0 and 1.2≤W₁/L₂≤4.0。

31. honeycomb ceramics as claimed in claim 10, it includes:

The sectional area of the fourth lane of constitutional repeating unit including outlet duct divided by constitutional repeating unit all channels The area fraction of sectional area is between 0.22 to 0.46.

32. honeycomb ceramics as described in claim 1, in which:

First passage and second channel include identical first quadrangle form；And

Third channel and fourth lane include identical second rectangular shape.

33. honeycomb ceramics as claimed in claim 32, wherein identical first quadrangle form includes square shape.

34. honeycomb ceramics as claimed in claim 33, it includes L₁=L₂, W₁≠W₂And L₁=L₂=W₂。

35. honeycomb ceramics as described in claim 1, it includes with constitutional repeating unit existing for stack orientation, wherein direct phase The exit passageway of adjacent constitutional repeating unit is present in the exit passageway of same column.

36. honeycomb ceramics as described in claim 1, it includes with constitutional repeating unit existing for decussate structure, wherein direct phase The exit passageway of adjacent constitutional repeating unit is not present in the exit passageway of same column.

37. honeycomb ceramics as described in claim 1, wherein at least some porous walls have wall thickness Tw, wherein 0.004 inch (0.102mm)≤Tw≤0.014 inch (0.356mm).

38. honeycomb ceramics as claimed in claim 37, wherein 0.006 inch of (0.152mm)≤Tw≤0.010 inch (0.254mm)。

39. honeycomb ceramics as described in claim 1, it includes 40%≤%P≤70%, and wherein %P is the open pore of porous wall Gap rate.

40. honeycomb ceramics as claimed in claim 39, it includes 40%≤%P≤60%.

41. honeycomb ceramics as claimed in claim 39, it includes 45%≤%P≤55%.

42. honeycomb ceramics as described in claim 1, it includes 38%≤import OFA≤62%, and wherein import OFA is that import is opened Mouth front face area.

43. honeycomb ceramics as described in claim 1, it includes 10 microns≤MPS≤18 micron, and wherein MPS is in porous wall The mean pore sizes in hole.

44. honeycomb ceramics as described in claim 1, it includes 75 hole track per inches²(483 duct/cm²)≤CD≤375 Hole track per inch²(2,420 duct/cm²), wherein CD is cell densities.

45. honeycomb ceramics as described in claim 1, it includes:

0.006 inch of (0.152mm)≤Tw≤0.010 inch (0.254mm), wherein Tw is the wall thickness of porous wall；

40%≤%P≤60%, wherein %P is the open porosity of porous wall；

10 microns≤MPS≤16 micron, wherein MPS is the mean pore sizes in the hole in the open pores of porous wall；

38%≤import OFA≤62%, wherein import OFA is the open front face area of honeycomb ceramics；And

1.2≤W₁/W₂≤2.5。

46. honeycomb ceramics as described in claim 1, wherein porous wall includes cordierite, silicon carbide (SiC), aluminium titanates, oxidation Aluminium (Al₂O₃), silicon-aluminium-nitride-oxide (Al₆O₂N₆Si), mullite, zeolite, fused silica or porous metals or they Combination.

47. a kind of method for filtering particle comprising:

Soot is captured in the particulate filter comprising honeycomb ceramics as described in claim 1.

48. honeycomb ceramics as described in claim 1, it includes L₁≠L₂。

49. honeycomb ceramics as claimed in claim 48, it includes W₁≥W₂。

50. honeycomb ceramics as claimed in claim 48, it includes W₁>W₂。

51. honeycomb ceramics as claimed in claim 50, it includes 0.5≤L₂/L₁≤1.25。

52. honeycomb ceramics as claimed in claim 48, it includes L₂>L₁And W₁>W₂。

53. honeycomb ceramics as claimed in claim 52, it includes W₂>L₁。

54. honeycomb ceramics as claimed in claim 52, it includes W₂<L₁。

55. honeycomb ceramics as claimed in claim 48, it includes L₂>L₁And W₁=W₂。

56. honeycomb ceramics as described in claim 1, it includes L₁=L₂And W₁=W₂。

57. honeycomb ceramics as described in claim 1, it includes W₁>L₂。

58. a kind of honeycomb ceramics comprising:

The porous wall of intersection in matrix comprising constitutional repeating unit pattern, the constitutional repeating unit have wall, the wall With wall thickness Tw, wherein 0.006 inch of (0.152mm)≤Tw≤0.010 inch (0.254mm), 40%≤%P≤60%, 10 microns≤MPS≤16 micron and 38%≤import OFA≤62%, wherein each constitutional repeating unit include the first duct, Second duct, third duct and the 4th duct, wherein the first duct, the second duct, third duct and the 4th duct are from import It extends parallel to each other on face to the axial direction of exit face, and there is quadrangle in the transverse plane orthogonal with axial direction Section, wherein each duct, which is blocked, to be clogged to limit intake channel and exit passageway in constitutional repeating unit, wherein Ge Gechong Complex structure unit includes:

The second channel limited by the second duct includes length L in cross section₂, width W₂With sectional area A₂, and second is logical Road and first passage share second sidewall；

The third channel limited by third duct includes length L in cross section₁, width W₁With sectional area A₃, the third is logical Road include third side wall and its with first passage share the first side wall；With

The fourth lane limited by the 4th duct includes length L in cross section₂, width W₁With sectional area A₄, and it is with Two channels share the 4th side wall and share third side wall with third channel, and

Wherein, first passage, second channel and third channel are intake channels, and it is rectangular shape that fourth lane, which is cross section, Exit passageway, and wherein, meet W₁≥W₂And L₁≠L₂At least one of, and constitutional repeating unit includes outside quadrangle Week, and

Wherein, Tw is wall thickness, and %P is the open porosity of porous wall, and MPS is mean pore sizes, and import OFA is honeycomb ceramics Inlet openings area.

59. a kind of honeycomb extrusion die comprising:

Die body, with inlet face and the exit face opposite with inlet face, the inlet face, which has from inlet face, to be extended Multiple feed openings into die body；With

Core array, which defines the slit array of the intersection at exit face and slit array from exit face extends to die head master In body, wherein at least some slits are connected to the one or more in the multiple feed opening, and the slit array of intersection is included in The first slit extended on entire exit face, and second slit that equally on entire exit face extends orthogonal with the first slit Group, core array include repetitive unit die head channel pore array, wherein the periphery of each promising quadrangle of repetitive unit die holes stage property Shape, the core array further include:

First part of the die head has length L in cross section_1’, width W_2’With sectional area A_1’,

Second part of the die head has length L in cross section_2’, width W_2’With sectional area A_2’,

Third part of the die head has length L in cross section_1’, width W_1’With sectional area A_3’, and

4th part of the die head has length L in cross section_2’, width W_1’With sectional area A_4’, the section tool of the 4th part of the die head There is rectangular shape, and

Wherein, part of the die head is arranged at least one of the first construction or the second construction, in which:

First construction is W_1’>W_2’And L_1’=L_2’And A_4’=A_3’>A_2’=A_1’,

Second construction is selected from one of following:

L_1’≠L_2’And A_4’>A_3’>A_2’<A_1’,

L_1’≠L_2’And A_4’>A_2’>A_3’<A_1’,

L_1’≠L_2’And A_3’>A_4’>A_1’<A_2’, or

L_1’≠L_2’And W_1’=W_2’And A_4’=A_2’>A_3’=A_1’。

60. honeycomb extrusion die as claimed in claim 59, wherein 1.2≤W_1’/W_2’≤10。

61. honeycomb extrusion die as claimed in claim 59, wherein 1.2≤W_1’/W_2’≤4.0。

62. honeycomb extrusion die as claimed in claim 59, wherein 1.2≤W_1’/W_2’≤2.5。

63. honeycomb extrusion die as claimed in claim 59, it includes A_1’=A_2’And A_3’=A_4’。

64. honeycomb extrusion die as claimed in claim 59, it includes A_4’=A_2’>A_3’=A_1’, L₁≠L₂And W₁=W₂。

65. honeycomb extrusion die as claimed in claim 59, it includes A_4’>A_3’>A_2’>A_1’, L₁≠L₂And W₁>W₂。

66. honeycomb extrusion die as claimed in claim 59, it includes A_3’>A_4’>A_1’>A_2’, L₁≠L₂And W₁>W₂。

67. a kind of method for manufacturing honeycomb ceramics, which comprises

Squeeze out batch mixtures by honeycomb extrusion die as claimed in claim 59, to generate the life for including honeycomb Green body.

68. the method as described in claim 67 further includes firing green to generate porous ceramic honeycombs.